Roofing panels with joining means

ABSTRACT

An aesthetic roofing panel or other aesthetic panel and method of producing it, comprising a substantially rigid panel shaped foam body having an upper surface which aesthetically smiluates roofing configuration; and a weather resistant sheet of a shape conforming to said upper surface; said weather resistant sheet bonded to said upper surface of said body; a plurality of said roofing panels having edge portions adapted to overlap adjacent edges of adjacent ones of said panels to shed water thereover; connecting respective cooperable interlocking means of each panel and an interlocking strip on a roof structure, respectively, for readily and securely fixing said panels on said roof structure; the disclosure also including a novel method for producing said roofing panels, comprising the forming of a thin weather resistant sheet of material into an aesthetic roof or other surface simulating configuration and casting a substantially rigid foam body under pressure contiguous with and bonded to said formed weather-resistant sheet; further, the method includes the provision of an interlocking means on said foam body and the securing of an interlocking strip on a roof or other structure and the installation of said panels on said roof or other structure by interlocking said interlocking means with said panel or a plurality thereof.

United States Patent 11 1 Turek I ROOFING PANELS WITH JOINING MEANSRobert L. Turek, Phoenix, Ariz.

[73] Assignee: Evans Products Company, Portland,

Oreg.

[22] Filed: June 17, 1974 [21] App]. No.: 479,765

Related US. Application Data [60] Division of Ser, No. 296,142, Oct 10.1972. abandoned, which is a continuation-impart of Ser. No. 235,331,March 16, 1972.

[75] Inventor:

[52] US. Cl. 52/546; 52/309; 52/313; 52/314; 52/520; 52/533; 52/547;52/555 [51] Int. C13... E04D 1/34; E04D 1/28; E04D 1/20; EO4D 1/26 [58]Field of Search 52/538, 309, 541,313, 52/551, 314, 547,316, 546, 533,554, 534,

[56] References Cited UNITED STATES PATENTS 1,063,674 6/1913 Freund52/533 X 3,173,229 3/1965 Weber 52/547 3,261,136 7/1966 Abner et a1 t 152/546 X 3,419,455 12/1968 Roberts 161/160 X 3,420,024 1/1969 Salvo t52/316 3,420,729 1/1969 Roberts..... 161/160 X 3,440,777 4/1969 Martin tr 52/551 X 3,605,369 9/1971 Merrill et a1. 52/560 X 3,608,261 9/1971French et a1... 52/316 3,626,439 12/1971 Kneisel 52/533 3,643,394 2/1972Johnsonm. 52/314 X 3,688,458 9/1972 Inmon 52/309 X 3,754,366 8/1973Jansson et a1 52/555 X 3,760,546 9/1973 Martin et al,.... 52/5553,807,113 4/1974 Turner 52/546 X FOREIGN PATENTS OR APPLICATIONS1,424,309 11/1965 France 52/309 1 1 Aug. 5, 1975 PrimaryE,\'aminer-Ernest R. Purser Assistant Examiner-Leslie A. Braun Attorney,Agent, or Firm-Robert E. Howard [5 7] ABSTRACT An aesthetic roofingpanel or other aesthetic panel and method of producing it, comprising asubstantially rigid panel shaped foam body having an upper surface whichaesthetically smiluates roofing configuration; and a weather resistantsheet of a shape conforming to said upper surface; said weatherresistant sheet bonded to said upper surface of said body; a pluralityof said roofing panels having edge portions adapted to overlap adjacentedges of adjacent ones of said panels to shed water thereover',connecting respective cooperable interlocking means of each panel and aninterlocking strip on a roof structure, respectively, for readily andsecurely fixing said panels on said roof structure; the disclosure alsoincluding a novel method for producing said roofing panels, comprisingthe forming of a thin weather resistant sheet of material into anaesthetic roof or other surface simulating configuration and casting asubstantially rigid foam body under pressure contiguous with and bondedto said formed weather-resistant sheet; further, the method includes theprovision of an interlocking means on said foam body and the securing ofan interlocking strip on a roof or other structure and the installationof said panels on said roof or other structure by interlocking saidinterlocking means with said panel or a plurality thereof.

7 Claims, 28 Drawing Figures PATENTED 5|975 3,897. 667

SHEET PATENTED AUG 5 I915 SHEET FIGJL PATENTED AUG 1975 SHEET FIG.2I.

PATENTEU B l 75 SHEET PIC-3.26.

ROOFING PANELS WITH JOINING MEANS This is a division of application Ser.No. 296,142 filed Oct. It 1972, now abandoned. which is acontinuation-in-part of my copending application, Ser. No. 235,331,filed Mar. 16, 1972.

BACKGROUND OF THE INVENTION A great variety of roofing has been used onbuildings and it has been desirable to produce roofing which ismechanically durable as well as being weather resistant. Further, it hasbeen desirable to produce roofing which is economical to manufacture andinstall as well as to maintain. The aesthetic features of cedar shakesas well as Spanish tile and many other roofing materials, are wellestablished and are highly desirable. There has been a need for theproduction of an economical roofing structure which aestheticallysimulates cedar shakes. Spanish tile, or other well known highlydesirable roofing. Furthermore, there has been a need for the productionof roofing which simulates the desirable roofing and yet which isrelatively economical to produce and install.

Additionally, it has been recognized that roofing, when installed inlarge panels, may economically be placed on sheathing of a roof therebysaving considerable labor cost as compared to conventional asphaltshingles or the like. Additionally, there have been a variety ofattempts to provide roofing materials which have substantial insulatingcapabilities as well as aesthetic features and economic practicality.

Heretofore, large roofing panels have been quite heavy and difficult toplace on roof sheathing by man ual labor.

Some prior art panels employ mineralized fiber boards produced underpressure with Portland cement and also utilizing concrete. These panelsare so heavy that a laborer cannot individually handle them when theyare produced in large sizes, as for example panels approaching 6 to 8feet in length and 3 to 4 feet wide. It has been recognized that asuitable lightweight panel of such dimensions can be handled by a singlelaborer and readily placed on a roof so as to rapidly cover a large roofand thereby improve the overall economy of roofing a building.

Heretofore it has been expensive economically to produce aestheticpanels having aesthetic configuration and particularly various panelsincluding doors or other aesthetic configuration.

SUMMARY OF THE INVENTION The present invention relates to roofing panelswhich are quite large and may range from 6 to 8 feet in length and 3 to4 feet in width, and these panels are produced of a substantially rigidfoam such as polyurethane foam or the like, and are covered with aweather resistant sheet which is formed so as to aesthetically simulateroofing configuration such as thick hand split cedar shakes, Spanishtile, or other aesthetic roofing or surface configuration. Thepolyurethane foam is cast and bonded to the lower side of the formedweather resistant sheet, forming an integral panel which is very lightand easily handled by a single laborer, and due to the insulatingcharacteristics of the polyurethane foam the overall roofing insulationis greatly enhanced. Each panel is provided with overlapping edgesadapted to overlap adjacent edges of an adjacent one of said panels andnovel water drain grooves are disposed in un derlying overlappedportions of said panels along generally inclined edges thereof. Thegenerally inclined edges of the panels are also provided withintermeshing irregularities which obscure the joinder of the panels witheach other, and the configuration of the formed weather resistant sheetexactly simulates the aesthetic configuration of roofing such as cedarshakes or Spanish tile, since molds of actual roofing of this type areutilized to form said weather resistant sheets in accordance with amethod of the invention.

A thin sheet of material, such as acrylic material, is formed inaccordance with the method of the invention to aesthetically simulateroofing configuration. This sheet is placed in a conforming mold andpolyurethane or other similar foam material is foamed in the mold whilethe mold is closed, thereby creating pressure in the mold for forcingthe foam into all of the areas of the formed sheet, and the foam isbonded to the sheet of material so that it forms an integral structurewherein a foam body is provided with an upper weather resistant skinhaving an upper surface which aesthetically simulates a desired roofingconfiguration.

The invention comprises a variety of means for connecting and securingthe roofing panels of the invention to roof structures such as woodensheathing or the like. One means for securing the panels to the roofcomprises interlocking members cast into the panels and having flangesprojecting from the lower surfaces of the panels which interlock withsecond locking strips which are nailed to the roof or sheathing, bothinterlocking structures in connection with the panel and the sheath'ing, respectively, having flanges slidably engageable with each other toallow the panels to be readily and firmly secured to a roof.

Another means of the invention for connecting the panels to a roof orwooden sheathing thereon comprises interlocking strips which areprovided with opposed flanges engageable in grooves in adjacent panelsat their inclined edges and these strips are also engageable in groovesin the panels near their lower edges and extend over thin upper edges ofthe panels and are disposed beneath overlapping portions of the panelsand may be nailed to roof sheathing or the like. The connecting stripsare progressively nailed to the roof sheathing as the panels are placedon the roof such that one connecting strip is nailed along one inclinededge of each panel and along one upper edge of each panel as the panelsare progressively placed on the roof and thereby secured. Eachconnecting strip which is placed adjacent an inclined edge of a panel isplaced such that one of its flanges overlaps a thin edge of the paneland an opposing flange of the strip so placed extends outward such thatit engages in a grooved area of the next panel being placed inend-to-end relation with the last mentioned panel, and whereby a thickoverlapping portion of the last mentioned panel extends over theconnecting strip and the relatively thin edge of the first mentionedpanel.

The method of the invention also includes novel connecting andinterlocking structure for installing the roofing panels of theinvention on the sheathing of a building roof.

The method includes the casting of a connecting member into the normallylower side of each panel when in the mold during the forming of thepolyurethane body, and also the placement of an interlocking means ingenerally horizontal strips on a roof sheathing such that the normallylower edge of the connecting means of each panel may be slidablydisposed beneath a generally upwardly directed edge of the interlockingmeans on the sheathing for readily and securely placing each largeroofing panel in secure interlocked relation with the sheathing of abuilding roof. The interlocking strips that are placed on the sheathingare preferably nailed down at their lower edges and their upper edgesare slightly spaced above the sheathing to allow the downwardlyextending lip of the connecting means of each panel to be placed underthe upwardly directed interlocking portion of the interlocking means onthe sheathing.

The foregoing method, as well as the means used for connecting thepanels to a building roof provide for the securement of large panelsonto a roof in a very simple manner which involves a minimum of time andlabor, and consequently provides for very desirable economy in theoverall production and installation of roofing in accordance with thepresent invention.

According to the invention, various panels having aestheticconfiguration may be produced in accordance with the invention, as forexample internal wall panels and/or doors having aestheticconfiguration.

Accordingly, it is an object of the present invention to provide a veryattractive and economical roofing for various buildings.

Another object of the invention is to provide a roof ing for buildingswhich has excellent insulating characteristics.

Another object of the invention is to provide light weight roofingpanels which are very easy to handle and which are very large, andconsequently may be used very rapidly to cover a large area of abuilding roof.

Another object of the invention is to provide a novel connecting andinterlocking means for panels on roof sheathing which is very secure,very simple, and easy to utilize during the installation of roofingpanels on roof structures.

Another object of the invention is to provide novel interlocking stripswhich may be nailed onto the roof of the building, and particularly onstructures such as wooden sheathing or the like, said strips havingopposed horizontally extending flanges adapted to be engaged in thegrooves of the panels of the invention and also adapted to extend overrelatively thin overlapped portions of adjacent panels of the invention.

Another object of the invention is to provide a novel method forproducing a hard foam panel with a weather resistant sheet on the uppersurface thereof.

Another object of the invention is to provide a novel method forproducing hard foam panels having weather resistant sheet structure onthe upper surface thereof; said sheet structure aesthetically simulatingroofing configuration such as the attractive configuration of thick handsplit cedar shakes or Spanish tile, or any other aesthetically desirableconfiguration.

Another object of the invention is to provide a rigid foam roofing panelof large dimensions having a weather resistant sheet bonded to the uppersurface thereof and which is particularly adapted to high volumeeconomic production and installation on roof structures.

Another object of the invention is to provide large roofing panelshaving novel overlapping edge structure adapted to shed water and alsohaving adjacent inclined edges of irregular intermeshing configurationwhich obscures the joinder of the panels at their adjacent edges,thereby providing for aesthetic simulation of the various irregularroofing configurations such as cedar shakes or the like.

Another object of the invention is to provide a method for producingvarious aesthetic panels such as doors or the like having aestheticconfiguration.

Further objects and advantages of the invention may be apparent from thefollowing specification, appended claims and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. I is a perspective view of aroofing panel in accordance with the invention, and produced to simulatethe aesthetic features of hand split thick cedar shakes;

FIG. 2 is an exploded plan view showing a plurality of the roofingpanels of the invention illustrating the manner in which they may beassembled in edge-toedge relationship to each other;

FIG. 3 is a reduced fragmentary bottom plan view taken from the line 3-3of FIG. I;

FIG. 4 is an enlarged fragmentary sectional view taken from the line 4-4of FIG. 2, but showing a pair of panels in installed overlapped relationto each other;

FIG. 5 is an enlarged fragmentary sectional view taken from the line 5-5of the panel shown in FIG. 3, but showing the panel on sheathing of aroof and showing the interconnecting and interlocking strips of thepanel and on the sheathing, respectively, for holding the panel on theroof sheathing;

FIG. 6 is an enlarged fragmentary sectional view taken from the line 66of FIG. 2 but showing the adjacent panels in overlapping relation toeach other;

FIG. 7 is a fragmentary bottom plan view of the panels shown in FIG. 6at the normally lower edges thereof;

FIG. 8 is a fragmentary sectional view taken from the line 8-8 of FIG.7;

FIG. 9 is a fragmentary view taken from the line 9-9 of FIG. 7, showingthe normally lower overlapping edges of a pair of adjacent panels;

FIG. I0 is a fragmentary sectional view of a building roof gablestructure showing roofing panels of the invention on the roof structureadjacent the gable, and showing a novel gable cap structure of theinvention together with gable cap connecting and interlocking meansadapted to secure the gable cap on the gable ridge timber of a roof andprovide for the overlapping of the cap structure with upper edges of theroofing panels of the invention;

FIG. II is a cross sectional view of the gable roof and cap structure ofthe invention as shown in FIG. 10;

FIG. 12 is an exploded perspective fragmentary view of a mold utilizedin accordance with the present method for producing roofing panels inaccordance with the present invention;

FIG. 13 is a transverse sectional view of the mold shown in FIG. 12 whenin closed position with a roofing panel being formed therein;

FIG. 14 is an enlarged fragmentary sectional view taken on the sameplane as FIG. 13 and showing the details of an interlocking strip beingcast in the panel;

FIG. 15 is a fragmentary perspective view of a modified locking strip ofthe invention adapted for us in locking the roofing panels of theinvention on building roof structure, such as sheathing or the like;

FIG. 16 is a fragmentary top or plan view of a roof showing several ofthe roofing panels of the invention secured thereon by locking stripssuch as shown in FIG.

FIG. 17 is an enlarged fragmentary sectional view taken from the line17-17 of FIG. 16',

FIG. 18 is an enlarged fragmentary sectional view taken from the line18-18 of FIG. 16;

FIG. 19 is a fragmentary end perspective view of a modified roofingpanel of the invention adapted for use in connection with the lockingstrip shown in FIG. 15;

FIG. 20 is a fragmentary end view of the modified panel taken from thesame end as FIG. 19 but showing the structure on enlarged scale toillustrate details thereof;

FIG. 21 is a view similar to FIG. 20 but showing the opposite end of thepanel from that as shown in FIG. 20;

FIG. 22 is an enlarged fragmentary view showing a cross section of anedge of one of the panels shown in FIG. 16 but showing the structure onenlarged scale;

FIG. 23 is a sectional view of a mold in which the structure shown inFIG. 22 is produced;

FIG. 24 is an enlarged fragmentary sectional view taken from the line2424 of FIG. 16;

FIG. 25 is a view similar to FIG. 18 but showing a modification of theinvention;

FIG. 26 is a sectional view of a seal shown in the modification of FIG.25;

FIG. 27 is a view similar to FIG. 18 showing a mastic seal betweenoverlapping portions of the roofing panels of the invention; and

FIG. 28 is a sectional view of the edges of panels of the inventioninstalled on the gabled end of a roof and showing clip means forsecuring cut ends of the panels at the end of the roof sheathing onwhich the panels are secured.

PREFERRED EMBODIMENTS OF THE INVENTION As shown in FIG. 1 of thedrawings, a roofing panel of the invention may be a large panel rangingin length from 6 to 8 feet and in width from 4 to 6 feet, it being notedthat these panels may be made in modules appropriate to the architectureupon which the panels may be used as roofing covers.

While the invention relates to roofing panels, it will be understoodthat various aesthetic panels, including doors or the like, may beproduced in accordance with the teachings of the invention.

Each panel is provided with a normally upper edge 20 and a normallylower edge 22. Additionally, each panel is provided with a firstgenerally or normally inclined edge 24 and a second normally inclinededge 26. Each edge 26 is adapted to overlap a respective edge 24 of alike panel and each lower edge 22 is adapted to overlap an upper edge 20of a like panel.

As shown in FIG. 2 of the drawings, the overlapping relation isillustrated by means of an exploded view and it will be seen that thenormally inclined edge 26 is provided with irregularities such as may beprovided by conventional shake shingles or the like, theseirregularities being designated 28, and they are adapted to mesh withirregularities 30 adjacent the edge 24 of a like panel, theirregularities 28 and 30 simulating the edges of cedar shakes andintermeshing with each other when the panels are disposed in adjacentrelation to each other, as shown in FIG. 2 of the drawings, so as toobscure the joinder of each of the panels at their adjacent inclinededges.

As a prime example, the panels shown in the drawings simulate theaesthetic configuration of thick hand split cedar shakes and thus theirregularities 28 and 30 at the inclined edges 26 and 24, respectively,of each panel are such as to provide for continuity of the aestheticfeatures of a shake roof when the panels are assembled in edge-to-edgeoverlapping relation, as shown in an exploded view in FIG. 2 of thedrawings.

The disclosure of FIG. 6 illustrates the overlapping of an edge 24 by anedge 26 of an adjacent one of the panels of the invention.

As shown in FIG. 6 of the drawings, the generally inclined edge 26 isprovided with a stepped ledge portion designated 32 which overlies arelatively thin portion 34 adjacent the edge 24, and this portion 34 isprovided with a groove 36 which is generally parallel to the inclinededge 24. This groove 36 is disposed beneath the overlapping ledge 32 fordraining water downwardly and this groove 36 has greater capacity thanthat amount of water which may flow between the ledge 32 and the uppersurface of the overlapped portion 34. In FIG. 6, the aforementionedirregularities 28 and 30 are slightly spaced apart and theseirregularities are meshed such as generally indicated in FIG. 2 bybroken lines, so as to obscure the edge-to-edge overlapping joinder ofthe panels of the invention when assembled on a roof.

Each lower edge 22 of each panel as shown in FIG. 4 overlaps an upperedge 20 of an adjacent panel and a ledge portion 38 at the lower edge 22of each panel is disposed slightly below the groove 36, as illustratedbest in FIG. 8 of the drawings. The ledge 38 adjacent the edge 24terminates at 40, as shown in FIG. 8 of the drawings, and theoverlapping ledge 32, as shown in FIG. 6 of the drawings, extends beyondthe terminal portion 40 of the overlapped portion 34 of the edge portion24. As shown at 42, the overlapping ledge 32 extends downwardly towardan overlapped upper edge 20 of an adjacent panel and thus an aestheticsimulating end 44 of one of the irregularities 28 extends beyond theedge 40 of the overlapped portions 34 so as to allow water from thegroove 36 to flow between the edge 40 and the downwardly extendingportion 42, shown in FIG. 8, this downwardly extending portion 42 beingone of the overlapping and intermeshing irregularities and particularlythe irregularity terminating at 44, as shown in FIGS. 1 and 8 of thedrawings, this edge simulating the lower edge of a shake shingle. Thebottom portion of this lower edge 44 is designated 46 in FIG. 8 of thedrawings, and it is slightly spaced above the upper surface of the panelwhich is overlapped thereby in order to allow for the passage of waterwhich passes downwardly through the groove 36 and between the edge 40and downwardly extending portion 42 of the irregularity portion 44, allas shown best in FIG. 8 of the drawings.

It will be noted that FIGS. 7 and 9 do not illustrate the overlappedupper edge 20 of the next lower panel, as shown in FIG. 8 of thedrawings.

As shown in FIGS. 8 and 9, the lower surface 46 of the respectiveirregular portion 28 is substantially above the lower surface 38 of theoverlapping ledge adjacent the lower edge 40 and accordingly acorresponding upper surface 48 near the upper edge of the panel shown inFIG. 8 is spaced from the lower surface 46 to allow for the passage ofwater which passes downwardly through the groove 36 and between thespaced portions 40 and 42. The lower edge 44 of the irregularity 28 thusextends below the groove 36 and does not expose it, and thereforemaintains aesthetic continuity of the entire assembly of the roofingpanels of the invention at their overlapping edges. Accordingly the edgeportions 44 hide the end of the grooves 36 which might otherwise beviewed by persons standing on the ground and looking upward toward thelower edges of the shake simulating configurations of the roofing panelsof the invention.

As shown in FIGS. 3 and of the drawings, each roofing panel is providedwith a normally lower surface 50 which is flat, and a normally uppersurface 52 which is formed into an aesthetic roofing simulatingconfiguration such as shakes, Spanish tile, or the like. The panel asshown in FIGS. 3 and 5 of the drawings is provided with a hard foam bodyportion 54 which is covered at its normally upper surface by a thin skinof water resistant material such as an acrylic sheet 56, which is formedinto an aesthetic configuration simulating conventional hand split thickcedar shakes.

The foam body 54 is cast, as will be hereinafter described, and imbeddedtherein is a first portion 58 of a connecting means 60. This connectingmeans 60 is an elongated structure having a general cross section asshown in FIG. 5 wherein barbed ridges 62 are cast and bonded into thepolyurethane foam body 54 for securely holding the first portion 58therein. A second connecting portion 64 if provided with a generallydownward extending edge 66, and it is slightly spaced from the bottom orlower side 50 of the body 54, and is adapted to be fitted beneath aninterlocking portion 68 of an interlocking means 70. This interlockingmeans 70 is provided with an offset portion 72 at a transition with arelatively thick nailer portion 74 through which nails 76 extend intoroof sheathing 78 for holding the connection means 70 in position on thesheathing 78 ofa roof structure. When the panels of the invention areinstalled, the lower edge portion 66 of the connecting means 60 isslidably moved under the upwardly directed edge 68 of the interlockingmeans 70 and thus the panels are secured to the roof structure on whichthe sheathing 68 is disposed.

It will be seen from the disclosure of FIG. 3 that there are two of theconnecting strips 60 imbedded in each panel body 54 and that one of themis near the lower edge 22 of each respective panel so as to preventdisconnection of the panel in any manner, as for example by wind orother forces.

lt will be seen that the interlocking means 60, as shown in FIGS. 5 and10, are nailed to the roof sheathing 78 by means of the nails 76, ashereinbefore de scribed.

When the interlocking means 60 are nailed onto the sheathing by thenails 76, the panels of the invention are placed on the sheathing andslidably moved downwardly into position such that the connecting portion67 of the connecting means 60 slides under the interlocking portion 68of the interlocking means 70, all as shown best in FIG. 5 of thedrawings.

Considering the fact that the panels are large, this manner of securingthe panels on the roof provides a very secure means for positively andaccurately locating the panels in edge-to-edge overlapped relationshipwith each other. but provides for a very rapid manner in which an entirelarge roof area may be quickly covered and efficiently roofed.

In accordance with the method of the invention, the foam body 54 of thepanel is provided with an integral conforming weather resistant sheet 52and the upper surfaces of these integral parts aesthetically simulateany desired roofing configuration.

The sheet 52 is at first a flat sheet and is placed in a mold having theaesthetic features of roofing configuration and is preferably vacuumformed in the mold to such configuration, then the sheet is placed in amold, as shown in FIGS. 12, 13 and 14, adjacent to a conforming backuplayer 80 having recessed cavities simulating the shape of shake shinglesor other roofing configuration, as desired. The formed sheet 52 is thusconformingly supported by the thick resilient backup sheet 80 andpolyurethane foam generating resin is placed in a cavity 82 and a moldplate 84 encloses one side of the cavity to provide for the formation ofthe normally lower surface of each panel cast in the cavity 82. Theplate 84 is backed by a solid steel plate 86 while the sheet backuplayer is carried by a relatively rigid conforming plate 88, which may bemade of figerglass or other suitable material, and adjacent this backupplate 88 is a steel plate 90 held in opposition to the plate 86. Movableholding members 92 support the plate 90, and movable holding members 94support the plate 86 and the cavity 82, as well as the sheet 52, backup80, and backup plate 88 are retained in a generally box-shaped frame 96forming an enclosed mold in which the foam generating resin may producesufficient pressure to create a very dense hard foam. As this cavity 82is closed, the backup plate 84, which serves to form the lower surfaceof the roofing panel, carries the connecting means 58 hereinbeforedescribed, relative to FIG. 5 of the drawings.

The connecting means 61, at its connecting portion 64, is held in arecess 98 in the face of the backup plate 84 and double-sided adhesivetape strips 100 and 102 hold the connecting means 58 of its connectingportion 64 in the recess 98. A cover strip 104 is secured on thenormally inner side of the connecting portion 64 in order to space itproperly from the normally lower surface 50 of the foam body 54 when itis cast against the backup plate 84, all as shown best in FIGS. 13 and14 of the drawings.

It will be seen that when the hard foam body 54 has been partially curedthat it may be removed from the mold cavity 82 and retained inconnection with the backup plate 84 to allow additional curing beforethe panel is stripped from the backup plate 84.

it will be appreciated that the removal of the partially cured hard foampanels in connection with the backup plate 84 allows the molds 96,together with their plates 86 and 90 to be cycled at the highestpossible rate compatible with partial curing of the panels and that afew extra backup plates 84 may serve to hold the roofing panels whilethey complete curing and during the time when the basic mold structuresare being cycled to produce additional panels.

in accordance with the method it will be appreciated that when thepolyurethane foam generating chemicals are placed in the cavity 82, thatgeneration of foam under pressure in the cavity 82 causes intimatebonding of the hard foam as it cures to the inner surface of the acrylicsheet 52 and thereby provides an integral relationship between theweather resistant acrylic sheet 52 and the hard foam body 54, such asshown in FIGS. 4 and 5 of the drawings.

It will be appreciated that the weather resistant sheet 52 may be eithervacuum formed or otherwise formed, such as in a press, and that thisacrylic sheet 52 is preferable; however, sheets of other material havingsubstantial weather resistance may be used. The thickness of the acrylicsheet 52 may range between 0.050 inch and 0.022 inch. The density of thefoam body may range between that provided by forming to a freeunpressurized condition and that which may be formed in accordance withthe overfilling of the mold cavity 82 such as to densify the foam 2 or 3times the density as compared to the foam which would be formed in afree ambient pressure condition. Accordingly, the method provides forthe varying of the density of the foam as well as the correspondingstrength of the panels, in accordance with requirements. The thicknessof the weather resistant sheet 52 may vary according to the materialsused and in accordance with the architectural requirements.

As related to the method, the backup plate 84 is provided with a facialayer of material such as a polyethylene sheet which is designated 106in FIG. 14, and this material 106 is compatible with the release of thepolyurethane foam body, the bottom side 50 of which is castthereagainst. Additionally, it will be understood that some releaseagent may be placed on the facia 106, if desired.

In the exploded view, FIG. 12, it will be seen that there are tworecesses 98 for holding two of the connecting means 60 in correspondencewith the disclosure of FIG. 3 as hereinbefore described.

The backup plates 84 are provided with manually usable handles 108 forcarrying these backup plates 84, together with a partially cured roofingpanel, as hereinbefore described. The handles 108 are disposed on eachend of the backup plates 84 and are within the confines of the frame 96and outwardly of the cavity 82, and preferably within the area of theresilient backup structure 80, as hereinbefore described.

Referring to FIGS. and 11 of the drawings, it will be seen that theinterlocking means 68 are placed on the sheathing and that the panelsare secured thereon in a manner as shown in FIG. 5. The sheathing issupported on rafters 110 coupled to a ridge timber 112, and rotatedbetween the rafters 110 on the ridge timber 112 are substantiallyH-shaped in cross section interlocking structures 114. These structures114, as shown in FIGS. 10 and 11 of the drawings, may be secured to thetimber by means of nails 116 in the sides of the tim her, and also nails118 extending through a horizontally disposed web 120 of the generallyHshaped in cross section structure of these interlocking means 114. TheH-shaped in cross section interlocking means 114 is provided with a pairof upwardly disposed spaced apart legs 122 between which the web 120 isdisposed and with which it is integral. A pair of downwardly extendinglegs 124 are spaced apart sufficiently to straddle the gable timber 112so as to allow the web 120 to rest on top of the gable timber 112.Accordingly, the interlocking means 114 is H-shaped in cross section andfixed onto the gable timber 112 in various locations between the rafters110, all as shown best in FIGS. 10 and 11 of the drawings.

The legs 122 and 124 on their outer sides are provided with a pluralityof vertically spaced apart downwardly declining buttress teeth 126 andthe legs 124 are continuity of the legs 122 so that all of the buttressteeth on the outer sides of these legs are in a substantially alignedvertical row and their buttress ledge portions are directed downwardly.

A substantially U-shaped inverted connecting means 128 is provided witha pair of downwardly directed legs 130 adapted to straddle the legs 122of the interlocking means 114. These legs 130, on their inner sides, areprovided with vertically spaced apart buttress teeth 130 which areupwardly inclined and have their locking faces directed upwardly so thatthey interlock with the buttress teeth 126 having downwardly directedfaces as hereinbefore described.

The legs 122 of the interlocking means 114, as well as the legs 130 ofthe connecting means 128 are resilient and therefore laterallyspringable to allow the buttress teeth 130 to progressively spring overand engage with the buttress teeth 126.

The H-shaped connecting means 128 is provided with lateral bars 132 castin a generally inverted V- shaped in cross section gable cap 134. Thisgable cap 134 is formed in accordance with the hereinbefore describedmethod and comprises a hard foam body 136 and a weather resistant sheet138. The upper surfaces of the body 136 and the weather resistant sheet138 are of a shape which simulates the aesthetic features andconfiguration of natural hand split heavy cedar shakes in the form of agable cap. These gable cap sections are made in substantially lengthyparts and the connecting means 128 may bridge several of theinterlocking means 114. I

After the roofing panels have been installed in a position as shown inFIG. 11, their upper edge portions 20 are well beneaththe lower surfaceof the body 136 and the lower outer edges 142 and 144 of the roofing capbody 136 extend downward well beyond the upper edges 20 of the roofingpanels of the invention, all as shown best in FIG. 11 of the drawings.Installation of the cap structure, as shown in FIGS. 10 and 11, merelyincludes the downward pressure on the cap until the hereinbeforedescribed buttress teeth 130 slide over and interlock with therespective buttress teeth 126, and when the cap has been pressed down toa level substantially in engagement with the roofing panels near theirupper edges 20, the installation of the gable cap is complete.

In the modified roofing panel connecting structure shown in FIGS. 15 to23, an interlocking strip is used in lieu of the interlocking strips 60and 70, as shown in FIG. 5 of the drawings.

In accordance with various installation requirements, the interlockingstrip 150 and the panels shown in FIGS. 16 to 23, may be preferred asmay hereinafter be apparent from the following description.

The interlocking strip 150 shown in FIG. 15 is provided with a basesurface 152 adapted to be contiguous with an upper surface 154 of roofsheathing 156, as shown in FIGS. 17 and 18 of the drawings.

The connecting strip 150 is provided with a flat upper surface 158substantially parallel with the flat base surface 152 and thisconnecting strip 150 is provided with an upstanding web 160 throughwhich nail receiving holes 162 extend so that nails 164 may be driventhrough these holes 162 and so that the nails may be driven into thesheathing 156 to a position at which the heads of the nails 164 engagethe upper surface 158 of the connecting strip 150 for holding the lowersurface 152 of the strip in tight contiguous engagement with the uppersurface 154 of the sheathing 156.

The web 160 is provided with integral oppositely directed flanges 166and 168 which are adapted to be engaged over thin overlapped edges ofthe panels and in recessed grooves respectively in adjacent edges of thepanels, as will be hereinafter described in detail.

The panels are designated 170 and are sbustantially identical inconfiguration. A plurality of these panels. as shown in FIG. 16 areshown on the sheathing 154 and are in place to illustrate theprogression of securing these panels on the sheathing 154 by means ofthe interconnectng or interlocking strips 150.

Each panel 170 is provided with a lower edge 172, an upper edge 174, andopposite inclined edges 176 and 178. Each inclined edge 176 isrelatively thin and overlapped by a flange 166 of one of theinterconnecting strips 150, as shown best in FIG. 18, and this edge 176is provided with a water drain groove 180 covered by an overlappingportion of the inclined edge 178 of the adjacent panel.

The inclined edge 178 of each panel is relatively thick and overlaps theedge 176 of the adjacent panel, as shown in FIG. 18, and each edge 178,beneath its overlapping portion is provided with a ledge 182 defined bya groove 184 in which the respective flange 168 of the interconnectingstrip 150 is disposed.

Similarly, the upper edge portions 174 of each of the panels 170 arethin, comparable in thickness to the edges 176 of the panels at theirinclined edges, and these upper edges 174 are clamped under respectiveflange portions 166 of the interconnecting strips 150.

' Further, each panel 172 at its lower edge is relatively thicker andoverlaps the upper edge 174 of the next lower panel. Each lowed edge172, beneath its overlapping portion, is provided with a ledge 186defined by a groove 188 in which a respective flange 168 of theconnecting strip 150 is disposed.

It will be understood that during the installation of each panel, thepanel is slidably moved downwardly such that its ledge portion 186 fitsbeneath the respective flange 168 while the edge 178 of the same panelis moved into position wherein its respective ledge 182 is slid underthe respective flange 168 of the respective connecting strip 150.Subsequently, a respective connecting strip 150 is secured to thesheathing by the nails 164 at a respective upper edge 174 of the paneland at a respective inclined edge 176 of the newly installed panel.

It will be noted that the interconnecting strips 150 which engage theinclined edges of the panels are relatively short and upper ends 190 ofthese strips 168 terminate a considerable distance from the upper edges174 of the respective panels. It will be seen, as shown in FIGS. and 21that the overlapping structure disclosed in FIG. 18 is tapered inthickness relative to a bottom side 192 and the thickness tapers towardthe upper edge 174, all as shown best in FIGS. 19, 20 and 21.

The upper edge 174 is provided with an overlapping ledge 194 whichoverlaps the thin edge 176 ofa respective panel, and these taperedportions 194 and 196 at the upper edges 174 have a combined thicknessequal to the distance between the lower surface 152 and the flange 166of the connecting member 150.

As indicated by a broken line in FIG. 17, the ledge 194 overlaps theupper surface 175 of the tapered portion 176 near the upper edge 174 ofeach panel and provides a combined overlapped thickness of therespective panels substantially equal to the overall thickness of theupper edge 174. The groove 184 in each panel, near its inclined edge178, terminated at 196, a substantial distance below the tapered ledge194 and the respective tapered portion 176 so that the combinedthickness of the overlap portions of the ledge 194 and the reducedthickness of the thin edge 176 equals a distance 199 which correspondsto the distance between the flange 166 and the base 152 of therespective connecting strip 150.

It will be seen that the respective ends 176 and 178 are provided withirregular edge configurations 198 and 200, which are intermeshing, andwhich provide a random edge-to-edge relationship which tends to obscurethe joinder of the adjacent panels such as the configuration of cedarshakes would appear. Accordingly, the irregularities on the inclinededges of the panels are similar to those hereinbefore described inconnection with FIGS. 1 and 2 of the drawings.

The overlapping ledge 194 of each panel near its inclined edge 178covers the respective interconnecting strip and a similar overlappingedge 202 extends over the upper edge 174 of a respective adjacent paneland also this overlapping ledge 202 covers the horizontally disposedinterconnecting strip 150 which has its flange 166 overlying therespective upper edge 174, of each panel.

As shown in FIG. 22, an overlapping lower edge 172 at its ledge 202extends considerably beyond the respective ledge I86 and correspondinggroove 188. This structure is formed in a mold assembly 204 havingcompression holding plates 206 and 208 which hold a rubber mold member210 having internal configuration 212 similar to cedar shakes or thelike, and disposed in the mold adjacent the plate 206 is a mold member214 having a lip 216 adapted to form the groove 188 in spaced relationfrom the end 218 of the mold cavity which forms the normally lower edge172 of the panel, as hereinbefore described.

The edge 178 of each panel is formed in similar detail structure in themold assembly 204 at substantially right angles to the structuredisclosed in FIG. 23, it being understood that the groove 184 is formedby another mold member similar to the mold member 214 and which isprovided with a lip similar to the lip 216 which forms the groove 184.

It will be understood that the modified interconnecting strip 150 andthe modified panels provide a preferred method of securing the panels toroof sheathing, since the connecting strips 150 may be nailed down tothe sheathing in an open position at the upper edge 174 and respectiveedge 176 of each panel whereupon successive panels are slidably movedinto place by sliding them downward and laterally such that therespective ledges 186 and 182 are engaged under the respective flanges168, of the connecting strips 150, all as hereinbefore described.

As shown in FIG. 25, a slot 226 is disposed in the upper overlappedportion of each of the panels 170 and disposed in this slot 226 in aseal 224 having a cross section such as shown in FIG. 26. The seal stripis provided with a substantially rectangular body portion 227 with anintegral tapered lip 229 which. as shown in FIG. 25, is deflectedlaterally to engage the lower side 194 of the overlapping panel portionnear the edge 200 thereof. This lip seal 229, when so deflected bymovement of the panel thereover in the direction of an arrow 1, sealsbetween the panels and prevents an amount of water which would overflowthe trough 180 to pass thereinto. This lip seal 229 also prevents thecollection of debris in the trough 180 and limits the possibility of thetrough being clogged and overflowed during a rainstorm.

In the modification as shown in FIG. 27, mastic 230 is disposed betweenthe surface 194 and the surface 175 of the respective panels 170 and themastic 230 may be used in lieu of the seal 224 as hereinbeforedescribed. The mastic 230 thus prevents undue flow of water into thetrough 180 so that overflow of the trough 180 may be prevented.

As shown in FIG. 28, one of the panels 170 at an edge 157 ofthesheathing 156 may be cut off at 232 adjacent to the edge 157 of thesheathing 156 which may be at the gable end of the building roof. inorder to hold down the cutoff edge 232, a fixture 234 is utilized, andthis fixture 234 may be made of sheet metal and is provided with aflange 236 which may be driven into the foam body of the panel 170 atits cutoff edge 232. Integral with the flange 236 is an offset portion238 having an integral vertical flange 240 through which nails 242 aredriven into the edge of the sheathing 156 at its end 157 for holding thefixture 234 in juxtaposition with the sheathing 156 and for retainingthe cutoff edge of the roofing panel securely on the sheathing 156.

it will be noted that the cutoff edge 232 and the outer portion of thefixture 234 are covered with an acrylic mastic coating 244, it beingunderstood that any suitable coating may be applied.

The fixtures 234 are elongated fixtures and may be made eof sheet metalor any other suitable material and the edge of the flange 236 mayreadily be pounded into the foam body of the panel at the cutoff edge232 thereof until the vertical flange portion 240 engages the edge 157of the sheathing 156.

It will be obvious to those skilled in the art that variousmodifications may be resorted to without departing from the spirit ofthe invention.

I claim:

I. A roofing panel and associated connecting means comprising incombination: a substantially rigid plastic foam body having normallyupper and lower surfaces; said upper surface having a thin, weatherresistant sheet bonded thereon having a roof surface simulatingconfiguration; said lower surface being substantially flat and adaptedto conform generally to roof sheathing or the like;

said panel having upper and lower longitudinal edges and first andsecond normally inclined edges disposed at opposite ends of said panel;said panel having said first inclined edge provided with a first ledgeportion adapted to extend above and overlap the second inclined edge ofan adjacent panel; the lower edge of said panel provided with a secondledge portion adapted to overlap and cover a respective upper edge of anadjacent panel; said panel at said first inclined edge and at said loweredge having a flange receiving groove, said groove being spaced fromsaid lower surface of said panel so as to coincide with the bottoms ofsaid first and second ledges, the thickness of said second inclined edgeof an adjacent panel, and with the thickness of the upper edge of anadjacent panel;

and means for joining a plurality of said panels comprising a pluralityof identically shaped elongated connecting means, each having a baseportion adapted to be fixed contiguous to roof sheathing or the likeupon which said lower surface of said panels are disposed, and a webportion extending upwardly from said base portion, and opposed flangesextending outwardly from the said upper part of said web portion; firstones of said connecting means having one of said opposed flanges engagedin said flange receiving grooves in the first inclined edge of eachpanel, the other of said opposed flanges overlying said second inclinededge of an adjacent panel; second ones of said connecting means havingone of said opposed flanges overlying an upper edge of each panel, theother one of said flanges being engaged in said flange receiving grooveat said second ledge of an adjacent panel.

2. The invention as defined in claim I, wherein: said foam body is ofpolyurethane material and said sheet is of acrylic material.

3. The invention as defined in claim 1, wherein: the thickness of eachpanel at said inclined edges being convergingly tapered toward saidupper edge.

4. The invention as defined in claim I, wherein: said web portion andbase portion having nail receiving openings therethrough for receivingsheathing penetrating nails therethrough.

5. The invention as defined in claim I, wherein: said second inclinededge of each panel having an upper surface provided with a recessedwater drain groove extending generally parallel to the respectiveinclined edge; said flange of said connecting means which overlaps andoverlies said second inclined edge, terminating at said recessed waterdrain groove.

6. The invention as defined in claim 1, wherein: said first one of saidconnecting means is covered by said first ledge portion.

7. The invention as defined in claim 1, wherein: said second one of saidconnecting means is covered by said second ledge portion.

I I l i l

1. A roofing panel and associated connecting means comprising incombination: a substantially rigid plastic foam body having normallyupper and lower surfaces; said upper surface having a thin, weatherresistant sheet bonded thereon having a roof surface simulatingconfiguration; said lower surface being substantially flat and adaptedto conform generally to roof sheathing or the like; said panel havingupper and lower longitudinal edges and first and second normallyinclined edges disposed at opposite ends of said panel; said panelhaving said first inclined edge provided with a first ledge portionadapted to extend above and overlap the second inclined edge of anadjacent panel; the lower edge of said panel provided with a secondledge portion adapted to overlap and cover a respective upper edge of anadjacent panel; said panel at said first inclined edge and at said loweredge having a flange receiving groove, said groove being spaced fromsaid lower surface of said panel so as to coincide with the bottoms ofsaid first and second ledges, the thickness of said second inclined edgeof an adjacent panel, and with the thickness of the upper edge of anadjacent panel; and means for joining a plurality of said panelscomprising a plurality of identically shaped elongated connecting means,each having a base portion adapted to be fixed contiguous to roofsheathing or the like upon which said lower surface of said panels aredisposed, and a web portion extending upwardly from said base portion,and opposed flanges extending outwardly from the said upper part of saidweb portion; first ones of said connecting means having one of saidopposed flanges engaged in said flange receiving grooves in the firstinclined edge of each panel, the other of said opposed flanges overlyingsaid second inclined edge of an adjacent panel; second ones of saidconnecting means having one of said opposed flanges overlying an upperedge of each panel, the other one of said flanges being engaged in saidflange receiving groove at said second ledge of an adjacent panel. 2.The invention as defined in claim 1, wherein: said foam body is ofpolyurethane material and said sheet is of acrylic material.
 3. Theinvention as defined in claim 1, wherein: the thickness of each panel atsaid inclined edges being convErgingly tapered toward said upper edge.4. The invention as defined in claim 1, wherein: said web portion andbase portion having nail receiving openings therethrough for receivingsheathing penetrating nails therethrough.
 5. The invention as defined inclaim 1, wherein: said second inclined edge of each panel having anupper surface provided with a recessed water drain groove extendinggenerally parallel to the respective inclined edge; said flange of saidconnecting means which overlaps and overlies said second inclined edge,terminating at said recessed water drain groove.
 6. The invention asdefined in claim 1, wherein: said first one of said connecting means iscovered by said first ledge portion.
 7. The invention as defined inclaim 1, wherein: said second one of said connecting means is covered bysaid second ledge portion.